LEGACY REPORT

ICC Evaluation Service, Inc.

PFC-3700
Issued October 1, 2003

[Link]

Business/Regional Office # 5360 Workman Mill Road, Whittier, California 90601 # (562) 699-0543 Regional Office # 900 Montclair Road, Suite A, Birmingham, Alabama 35213 # (205) 599-9800 Regional Office # 4051 West Flossmoor Road, Country Club Hills, Illinois 60478 # (708) 799-2305

Legacy report on the 1997 Uniform Building Code and the 2000 International Building Code
DIVISION: 03CONCRETE Section: 03410Plant-Precast Structural Concrete AERCON ROOF, FLOOR, CURTAIN WALL AND PARTITION AUTOCLAVED LIGHTWEIGHT CONCRETE PANELS AND PRECISION BLOCKS AERCON FLORIDA, LLC 3701 COUNTY ROAD 544 EAST HAINES CITY, FLORIDA 33844 1.0 SUBJECT AERCON Roof, Floor, Curtain Wall and Partition Autoclaved Lightweight Concrete Panels and Precision Blocks. 2.0 2.1 DESCRIPTION General: bars are protected with a minimum 0.02-inch-thick (0.5 mm) anticorrosion treatment, and with a minimum 1/2-inch (12.7 mm) cover of autoclaved concrete. The average moisture content, at delivery, is approximately 30 percent by weight. All metal connectors, fasteners and accessories used with the material must be corrosion-resistant material determined by Aercon Florida, LLC, to be compatible with the precast units. 2.2.2 Design: All units must be designed in accordance with ACI-523.2, published by the American Concrete Institute, and either Section 1926 of the UBC or Appendix A of Building Code Requirements for Reinforced Concrete (ACI 318-99), published by the American Concrete Institute, for buildings constructed in accordance with the IBC. Use of AERCON panels, as a portion of the structural frame, is limited to Seismic Zones 0, 1 or 2 (UBC) or Seismic Design Categories A or B (IBC). 2.2.3 Roof and Floor Units: [Link] General: The units are manufactured with tongueand-groove joints along the longer dimension, and chamfered edges, as illustrated in Figure 2 of this report. Tables 4 and 5 of this report indicate allowable loads for roof and floor units. Diaphragm action must be assumed with these units, based upon calculations and construction details provided to justify this assumption. Units must have a minimum 2-inch (51 mm) bearing. Typical details of anchorage to structural steel are shown in Figure 3 of this report. Typical details are intended as a guide only, and when used must be substantiated by structural calculations and approved by the building official. Anchorage stirrups must be provided at alternating joints. Steel reinforcement within the top groove must have a minimum length equal to one-third the span. All grooves must be filled with concrete or grout. Maximum cantilever of a unit must be limited to double its thickness, unless substantiated by structural calculations or other data submitted to and approved by the building official. Approved roof coverings must be used on all roof slabs. Floor slabs must be protected from moisture and abrasion by application of an appropriate topping, such as sand and cement mixture. [Link] Fire Resistance: The minimum 8-inch-thick (203 mm), 2-foot-wide (610 mm), reinforced floor panels and roof panels have a restrained assembly fire resistance rating of 4 hours. The same panels have an unrestrained assembly fire resistance rating of 1 hour when the reinforcing in the panels

AERCON is a noncombustible, siliceous material manufactured from a mixture of sand, quicklime and portland cement, aerated with aluminum powder and cured in a highpressure autoclave. The reinforced panels are manufactured in three strength categories, identified as ACR2, ACR3 and ACR4, with nominal dry densities of 25 lb./ft.3 (400 kg/m3), 31 lb./ft.3 (500 kg/m3) and 40 lb./ft.3 (600 kg/m3), respectively. (See Table 2.) The Precision Block products are manufactured in three strength categories identified as AC2, AC4 and AC6, with nominal dry densities of 25 lb./ft.3 (400 kg/m3), 31 lb./ft.3 (500 kg/m3) and 40 lb./ft.3 (600 kg/m3), respectively. (See Table 3.) The AERCON panels and precision blocks are alternatives to concrete and masonry described in the 1997 Uniform Building Code (UBC) and the 2000 International Building Code (IBC). The blocks and panels must be assembled using AERCON thin-bed mortar and grout. All of the products are permitted to be sawn, drilled or nailed. The panel units are used as structural roof and floor units, bearing wall panels, nonloadbearing curtain walls and partition panels. The blocks are used as reinforced and unreinforced exterior and interior bearing and nonload-bearing walls. Figure 1 of this report illustrates typical products. Table 1 of this report provides the product sizes. 2.2 Reinforced Panels:

2.2.1 General: The panels are reinforced with smooth colddrawn steel bars complying with ASTM A 82. Transverse bars must be welded to longitudinal reinforcement to provide reinforcement anchorage. Reinforcing steel bar diameters range from 3/16 inch (4 mm) to 1/2 inch (12 mm). All reinforcing

ICC-ES legacy reports are not to be construed as representing aesthetics or any other attributes not specifically addressed, nor are they to be construed as an endorsement of the subject of the report or a recommendation for its use. There is no warranty by ICC Evaluation Service, Inc., express or implied, as to any finding or other matter in this report, or as to any product covered by the report.

Copyright 2003

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Page 2 of 9 has a minimum cover of 7/8 inch (19.1 mm). Panel joints are reinforced with No. 3 deformed steel reinforcement bars and packed with normal-weight concrete. For restrained assemblies, perimeters are restrained by ring beams measuring 6 inches (152 mm) wide by the depth of the panels. The ring beams are reinforced with two No. 4 deformed steel reinforcement bars, placed at one-third and two-thirds the depth of the beam; and consist of normalweight concrete with fNc = 3,000 psi (20.67 MPa). The loading is calculated in accordance with Section 2.2.2 and is limited to 110 psf (5.3 kPa) live, 145 psf (6.9 kPa) total. 2.2.4 Curtain Walls: All units are nonbearing and are designed to resist wind loads as set forth in Table 6 of this report. Wall units have two layers of equal reinforcement and are placed with longitudinal edges either vertical or horizontal. Wall units placed vertically are produced with tongue-andgroove vertical edges as shown in Figure 4. Typical connections to structural steel are shown in Figures 5, 6 and 7 of this report. Exterior panels and their connections must comply with the requirements of Section 1632 and 1633 of the UBC or Section 1621 of the IBC. Typical connections are intended as a guide only, and when used must be substantiated by structural calculations or other data submitted to and approved by the building official. Typical exterior surface treatment involves the application of two coats of water-repellent, but not impermeable, acrylic paint. The first coat is brushed on and the second, containing coloring and optional mineral grains for texture, is roll- or spray-applied. The joints are painted prior to treatment of the surface, after which an elastic sealing compound is applied to expansion joints. Interior surfaces must be given an initial sand spackle coating before the surfaces are painted or wallpapered. 2.2.5 Partition Panels: [Link] General: These panels are nonload-bearing and are designed for 5 psf (34 kPa) lateral loads perpendicular to the surface. The panels are 24 inches (608 mm) wide; 3 or 4 inches (75 mm or 102 mm) thick; are available in lengths between 7 feet and 10 feet (2134 mm and 3048 mm), in 2inch (51 mm) increments; and have a rectangular cross section with reinforcement placed at mid-depth. Partition panels must be joined with a cement-based adhesive provided by the manufacturer. Adequacy of connections to ceilings and floors must be justified by structural calculations or other data submitted to and approved by the building official. [Link] Fire Resistance: The 4-inch-thick (102 mm) Category ACR4 panels have a three-hour fire-resistance rating in a nonload-bearing configuration. The panels must be installed vertically, and the joints must be mortared using AERCON mortar described in Section 2.3.1. The exterior and interior surfaces need not be coated or covered with any other finishing materials. Horizontal steel reinforcement is minimum W-3 smooth wire, spaced 48 inches (1219 mm) on center, and vertical steel reinforcement is minimum W-2 smooth wire, spaced 12 inches (305 mm) on center. Reinforcement must be centered in the panel. 2.2.6 Miscellaneous: Precast units must be at least 12 inches (305 mm) above adjacent grade unless appropriately protected from absorption of moisture. Grooves for electrical wiring and holes for junction boxes are permitted to be cut or routed on-site when substantiated by structural calculations. Openings in roof and floor panels that are field-cut must have additional reinforcement substantiated by structural calculations or other data. 2.3 Precision Blocks:

PFC-3700

2.3.1 General: The AERCON Precision Blocks are solid blocks manufactured from the same material and by the same method as used for the AERCON reinforced panels. The blocks are used for either reinforced or nonreinforced, exterior or interior, load-bearing or nonload-bearing walls. The dimensions for the blocks are presented in Table 1 of this report. The tolerances are 1/16 inch (1.5 mm) for all dimensions. [Link] AERCON Thin-bed Mortar: AERCON Precision Blocks are laid with a proprietary AERCON thin-bed mortar, supplied in a dry, ready-to-mix form, containing fine sand and/or crushed marble, cement, lime and plasticizing and water-retaining additives. Packaged in 55-pound (25 kg) bags, the mortar has a shelf life of 12 months. Each bag is combined with 1.75 gallons (6.6 L) of clear water and mixed for two minutes. The mortar has a minimum compressive strength of 1,000 psi (6.9 MPa) at 28 days. The mortared joints are approximately 1/16 inch (1.5 mm) thick. 2.3.2 Design: The structural design must comply with Chapter 21 of the UBC or ACI 530-99 (IBC). Allowable design stresses and properties are presented in Table 3 of this report. Use of AERCON Precision Blocks as a portion of the structural frame is limited to Seismic Zones 0 and 1(UBC) or Seismic Design Category A (IBC). 2.3.3 Exterior and Interior Protection: Cementitious stucco or other approved exterior wall claddings need to be applied over exterior walls. The interior surfaces need to be coated with cementitious or gypsum-based plaster or other interior wall finishes. Basement walls must be built with strength class AC4 or AC6 Precision Blocks only. For this application, precautions must be taken to allow for the drying of the wall. This is achieved either by applying impermeable protection below-grade on the outside, in which case heatdrying takes place toward the inside, or by applying a noncapillary air-permeable cover (e.g., mineral wool mat) on the outside, below ground level. In the latter case, the drying takes place through both sides of the basement wall. 2.3.4 Fire Resistance: The minimum 6-inch-thick (200 mm) Precision Blocks have a bearing wall fire resistance rating of 4 hours and a nonbearing wall fire resistance rating of 4 hours. The density of the Precision Blocks must be 25 to 43 pcf (400 to 650 kg/m3). The Precision Blocks must be laid in a running bond, and the head and bed joints mortared with AERCON mortar. For bearing walls, the load must be calculated in accordance with Section 2.3.2, and is limited to 11,560 plf (168.7 kN/m). 2.4 Installation:

The units must be installed in accordance with this report, and the UBC or the IBC, as applicable, and with the approved structural plans. Copies of the plans and this report must be available at the jobsite at all times during installation. The instructions within this report must govern if there are any conflicts between the manufacturers instructions and this report. 2.5 Special Inspection:

2.5.1 UBC: Special inspection of concrete reinforced panels, structural masonry precision blocks, and fastener placement shall conform to Section 1701.5 of the UBC. 2.5.2 IBC: Special inspection of concrete reinforced panels, structural masonry precision blocks, and fastener placement shall conform to Section 1704 of the UBC.

Page 3 of 9 2.5.3 Inspectors Duties: The special inspectors duties include verifying panel, masonry unit and mortar identification; panel and unit placement; mortar preparation; and application. 2.6 Identification: 4.2

PFC-3700 All units are designed in accordance with the applicable code, using the allowable stresses in this report. Design calculations and details for specific applications are furnished to the building official, and verify compliance with this report and the applicable code. Panels are produced by Aercon Florida, LLC, at 3701 County Road 544 East, Haines City, Florida, with inspections by Underwriters Laboratories (AA-668). Data establishing compliance of Precision Blocks with the density compressive strength requirements for each class as described in this report accompanies each shipment and is submitted to the building official for each project. Inspection and installation of AERCON Reinforced Panels complies with the requirements set forth in the applicable code for precast concrete inspection, including special inspection described in Section 2.5 of this report. Inspection and installation of AERCON Precision Blocks units complies with the requirements set forth in the applicable code for structural masonry, including special inspection described in Chapter 17 of the applicable code.

4.3

All panels produced in accordance with this report bear the name of the manufacturer (Aercon Florida, LLC), the piece mark number, the strength class, the name of the inspection agency (Underwriters Laboratories), and the evaluation report number (ER-3700). Each cube or pallet of Precision Blocks produced in accordance with this report bear a label with the strength class, the name of the inspection agency (Underwriters Laboratories), and the evaluation report number (ER-3700). Mortar is identified with the product name, manufacturers name (Aercon Florida, LLC) and address, weight, mixing instructions, and evaluation report number (ER-3700). 3.0 EVIDENCE SUBMITTED Data in accordance with the ICC-ES Interim Criteria for Concrete and Concrete Masonry Walls (AC15), dated June 2003; reports of tests in accordance with UBC Standard 7-1 (ASTM E 119); and a quality control manual. 4.0 FINDINGS That the AERCON Autoclaved Lightweight Concrete Panels and Precision Blocks described in this report comply with the 1997 Uniform Building Code and the 2000 International Building Code, subject to the following conditions: 4.1 Material is permitted materials are required. where noncombustible

4.4

4.5

4.6

4.7

This report is subject to re-examination in one year.

TABLE 1PRODUCTS AVAILABLE1 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 PRODUCT Length AERCONPrecision Block AERCONTongue and Groove Precision Block AERCONU-Block AERCONClean-Out Block AERCONLintel AERCONTongue and Groove Modular Block AERCONInterior Wall Panel AERCONLoad-bearing Wall Panel AERCONFloor Panel AERCONRoof Panel AERCONCored Precision Block 20 and 24 inches 20 and 24 inches 24 inches 8 inches 8 feet 0 inch, maximum 24 inches 9 feet 8 inches, maximum 12 feet 0 inch, maximum 20 feet 0 inch, maximum 20 feet 0 inch, maximum 24 inches AVAILABLE NOMINAL DIMENSIONS Height/Thickness 8 inches 8 inches 8 inches 8 inches 8 inches 24 inches 3, 4, 4.5 and 6 inches 8, 10 and 12 inches 8, 10 and 12 inches 8, 10 and 12 inches 8 inches Width 3, 4, 4.5, 6, 8, 10 and 12 inches 4, 4.5, 6, 8, 10 and 12 inches 8, 10 and 12 inches 8, 10 and 12 inches 4, 6, 8, 10 and 12 inches 4, 6, 8, 10 and 12 inches 24 inches 24 inches, maximum 24 inches, maximum 24 inches, maximum 8, 10 and 12 inches

For SI: 1 inch = 25.4 mm, 1 foot = 305 mm.

Products are keyed to Figure 1 by item number.

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TABLE 2REINFORCED PANELS ALLOWABLE STRESSES AND PHYSICAL PROPERTIES ACR2 Minimum compressive strength, fcN, psi Allowable compressive strength, psi Allowable flexural compressive strength, psi Allowable flexural tensile strength, psi Allowable shear strength, psi Modulus of elasticity (E), psi Coefficient of thermal expansion, 1/F Thermal conductivity, BtuAin./(ft AhAF)
2

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STRENGTH CATEGORIES ACR3 470 118 157 24.0 12.0 260 103 4.4 10-6 0.97 39.0 31 1.6 ACR4 626 157 209 24.0 17.0 360 103 4.4 10-6 1.11 49.0 40 1.6 313 78 104 24.0 8.0 190 103 4.4 10-6 0.80 32.0 25 1.6

Design dead weight, pcf Dry density, pcf

W For SI: 1 psi = 6.89 kPa, 1/F = 1/0.556C, 1 pcf = 16.018 kg/m3, 1 BtuAin./(ft2AhAF) = 0.1441 m A K . TABLE 3PRECISION BLOCKS ALLOWABLE STRESSES AND PHYSICAL PROPERTIES Minimum compressive strength of masonry, fNm,, psi Allowable compressive strength of masonry, psi Allowable flexural compressive strength, psi Allowable flexural tensile strength, psi Allowable shear strength, psi Modulus of elasticity (E), psi Coefficient of thermal expansion, 1/F Thermal conductivity, BtuAin./(ft AhAF)
2

STRENGTH CATEGORIES AC2 345 85 115 24 9 190 103 4.4 10-6 0.80 31 25 1.6 AC4 570 140 190 24 15 260 103 4.4 10-6 0.97 37 31 1.6 AC6 855 210 285 24 22 360 103 4.4 10-6 1.25 47 40 1.6

Design dead weight of masonry, pcf Dry density of a masonry unit, pcf

W For SI: 1 pcf = 16.018 kg/m3, 1 psi = 6.89 kPa, 1/F = 1/0.556C, 1 BtuAin./(ft2AhAF) = 0.1441 m A K .

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TABLE 4ROOF UNITS (24-INCH WIDTH)1,2,3 ALLOWABLE SUPERIMPOSED LOAD (psf) 22.5 THICKNESS (inches) 4 6 8 10 4 6 8 10 4 6 8 10 NOMINAL LENGTH (feet) 8 X X X X X X X X X X X X X X X 10 X X X X X X X X X X X X X X X 12 NP X X X NP X X X NP X X X X X X 14 NP X X X NP X X X NP X X X X X X 16 NP X X X NP X X X NP X X X NP X X 18 NP X X X NP NP X X NP NP X X NP X X

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20 NP NP X X NP NP X X NP NP X X NP NP X

32.8

43.0

6 8 10 For SI: 1 inch = 25.4 mm, 1 foot = 305 mm, 1 psf = 47.89 Pa. 63.5
1

All roof units are designed for deflection of less than L/360 of the span due to live loads and less than L/240 of the span due to live load and dead load. 2 Tolerances: Length: 1/4 inch. Width: 1/16 inch. Thickness: 1/16 inch. 3 X= Permitted; NP = Not permitted. TABLE 5FLOOR UNITS (24-INCH WIDTH)1,2,3 ALLOWABLE SUPERIMPOSED LOAD (psf) 48.0 THICKNESS (inches) 6 8 10 NOMINAL LENGTH (feet) 8 X X X X X X 10 X X X X X X 12 X X X X X X 14 NP X X NP X X 16 NP X X NP X X 18 NP NP X NP NP X 20 NP NP X NP NP NP

6 8 10 For SI: 1 inch = 25.4 mm, 1 foot = 305 mm, 1 psf = 47.89 Pa. 83.5
1

All floor units are designed for deflection of less than L/360 of the span due to live loads and less than L/240 of the span due to live load and dead load. 2 Tolerances: Length: 1/4 inch. Width: 1/16 inch. Thickness: 1/16 inch. 3 X= Permitted; NP = Not permitted. TABLE 6CURTAIN WALL UNITS (24-INCH WIDTH)1,2 ALLOWABLE SUPERIMPOSED LOAD (psf) 30.8 THICKNESS (inches) NOMINAL LENGTH (feet) 10 X X X 14 X X X 18 X X X 20 X X X

6 8 10 For SI: 1 inch = 25.4 mm, 1 foot = 305 mm, 1 psf = 47.89 Pa.
1 2

All wall units are designed for deflection of less than L/240 of the span due to live loads. Tolerances: Length: 1/4 inch. Width: 1/16 inch. Thickness: 1/16 inch. 3 X= Permitted.

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PFC-3700

FIGURE 1AERCON PRODUCT LINE (See Table 1 for product description and item number)

FIGURE 2CROSS SECTION OF TYPICAL ROOF AND FLOOR UNITS

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FIGURE 3TYPICAL ANCHORAGE OF ROOF AND FLOOR UNITS TO STRUCTURAL STEEL FRAME

FIGURE 4CROSS SECTION OF TYPICAL VERTICAL WALL UNITS

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FIGURE 5TYPICAL CONNECTION OF HORIZONTAL WALL UNITS TO STRUCTURAL STEEL FRAME (PLAN)

FIGURE 6TYPICAL CONNECTION OF VERTICAL WALL UNITS TO STRUCTURAL STEEL FRAME (PLAN)

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FIGURE 7TYPICAL CONNECTION OF VERTICAL WALL UNITS TO STRUCTURAL STEEL FRAME (PLAN)